Dissolution type thermal transfer film for three dimentional patterns and method for manufacturing the same

ABSTRACT

In the present invention concerning a dissolution type thermal transfer film for three dimensional patterns and a method for manufacturing the same film, the simplification and speed of a pollution-free dry printing process and various types of decoration are achieved by transferring the thermal transfer film according to the invention to an article to be decorated made of wood or plastic molded material only with the use of heat and pressure and by subsequently forming a desired decoration in three-dimensional pattern through two dissolution processes, wherein the thermal transfer film comprises a base film consisting of polyester, polypropylene or polyvinylchloride without a mat agent or coated with a mat agent to provide a unglazed film, an optional releasing layer based on acrylic resin as the main component having separability to be mounted on the top of the base film, a print layer made of a water-soluble acryl-based resin, or water-soluble or alcoholic vinyl-based resin having dissolving power on the top of the optional releasing layer, a metal powder-printed layer or metal vapor-deposited layer, a thermosetting protective layer, a secondary acryl-based print layer and finally an adhesive layer coated in that order.

FIELD OF THE INVENTION

[0001] The present invention relates to a dissolution type thermaltransfer film for three dimensional patterns and a method formanufacturing the same, which allow the formation of ornamental threedimensional patterns with an improved performance based on the step ofdirectly transferring the thermal transfer film already made to theobject of interest and a subsequent step of partially dissolving thetransferred film, and further to a process wherein a base film ofpolyester, polypropylene or polyvinylchloride or a base film of the samekind but unglazed through coating with a mat agent is laminated withvarious functional layers through the dry printing process andtransferred to the surface of wood or plastic molded material to formthree dimensional patterns with the help of two auxiliary dissolvingsteps.

BACKGROUND OF THE INVENTION

[0002] Generally, in case that the decorative work is conducted for thearticles including picture frames, furniture, interior parts and thelike made of wood or plastic molded material, the formation of threedimensional patterns on the surfaces of those articles is achievedthrough a serial operations including repeated paintings, dryings anddissolutions. Specifically, the base color is primarily coated on aframe, another color is coated on the primary color and so on, then thecoated colors are dried and subsequently the colors are partiallyremoved or dissolved to form desired three dimensional or raisedpatterns. This process involves a fundamental problem because thecoating operations including the partial dissolving operation should beconducted manually and so excessive working time is required due to thecomplexity and tediousness of the operation, the efficiency ofproduction is low together with the increased cost and furthermore thereis a limitation in providing a variety of designs and patterns.

[0003] Accordingly, there has been a continuous demand for a proposal ofmeasure for a variety of patterns and enhanced work efficiency.

SUMMARY OF THE INVENTION

[0004] The invention was created to resolve the above-described problemwith the conventional art in connection with coating of a paint andremoving of the dried color coating and the object of the invention isto provide a thermal transfer film for three dimensional patterns and amethod for manufacturing the same film wherein the formation of threedimensional patterns is very easily achieved, working time is shortenedwith the reduced manpower to result in markedly reduced manufacturingcost due to the increased efficiency and moreover a variety ofhigh-valued three dimensional patterns and designs are realized, basedon the basic idea of substantially dry printing of thermal transferfilms in a process of direct thermal transfer to the articles to bedecorated by using only heat and pressure, followed by dissolving theunwanted portions out from the printed plastic film by taking theadvantage of the property of a solvent capable of dissolving a plastic.

[0005] The object is achieved according to an aspect of the invention bytransferring the thermal transfer film according to the invention in drystate to an article to be decorated made of wood or plastic moldedmaterial only with the use of heat and pressure and by subsequentlyforming a desired decoration in three-dimensional pattern through twodissolution processes, wherein the thermal transfer film comprises abase film consisting of polyester, polypropylene or polyvinylchloridewithout a mat agent or coated with a mat agent to provide a unglazedfilm, an optional releasing layer based on acrylic resin as the maincomponent having separability to be mounted on the top of the base film,a print layer made of a water-soluble acryl-based resin, orwater-soluble or alcoholic vinyl-based resin having dissolving power onthe top of the optional releasing layer, a metal powder-printed layer ormetal vapor-deposited layer, a thermosetting protective layer, asecondary acryl-based print layer and finally an adhesive layer coatedin that order.

[0006] The object is also achieved according to another aspect of theinvention by a method for manufacturing a thermal transfer film forthree dimensional patterns, which comprises the steps of: coating theacryl-based resin, as the main component, by using ketone-based solvent,acetate-based solvent or toluene to form a releasing layer, on a basefilm consisting of polyester, polypropylene or polyvinylchloride withouta mat agent or coated with a mat agent to provide a unglazed film; onthe releasing layer, coating the primary print layer consisting of anink made from a water-soluble acryl-based resin, or water-soluble oralcoholic vinyl-based resin together with a dyestuff, methanol, ethanol,IPA and water; on the primary printed layer, coating a metal powder inkor vapor-depositing a thin metal layer in vacuum; on the metal layer,coating a protective layer of acryl-based resin or acrylicurethane-basedresin together with ketone-based solvent, acetate-based solvent,toluene, alcohol solvent and curing agent, as the layer for preventingthe under-laid print layer from dissolving; on the protective layer,coating a secondary print layer; and coating an adhesive layer foradhesion with an article to be joined.

[0007] Further characteristics and advantages of the invention will beevident from the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008]FIG. 1 shows the enlarged longitudinal cross section of adissolution type thermal transfer film according to the invention, and

[0009]FIG. 2 shows the flow diagram for manufacturing a dissolution typethermal transfer film according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0010] The dissolution type transfer film for three dimensional patternsand the method for manufacturing the same film will be described indetail along with a preferred embodiment in conjunction with theaccompanying drawings.

[0011] The dissolution type transfer film for three dimensional patternsaccording to the invention is in the form of laminate consisting of 7layers, as shown in FIG. 1.

[0012] As the base film, a glazed or unglazed and thermally stablepolyester-based, polypropylene-based or polyvinylchloride-based film, orotherwise one or more of the aforementioned three types of films coatedwith mat agent for unglazed property may be used. A releasing layer 2 isformed by uniformly coating, on the base film 1 of a solution typetransfer film A, a composition of acryl-based resin(e.g. MMA) dissolvedin a solvent based on ketone, acetate or toluene. This releasing layer 2functions to induce peeling property between the primary layer 3 and thebase film 1. As the case may be, the releasing layer may be dispensedwith. Preferably the resin weight of the releasing layer may amount to15 to 20 wt. %.

[0013] Then the primary print layer 3 is formed in a thin film bycoating a mixture which is prepared by dissolving a water-soluble acrylresin, water-soluble or alcoholic vinyl resin in a solvent likemethanol, ethanol, IPA or water and uniformly dispersing an arbitrarilychosen weatherproof pigment therein to prepare an ink. After the primaryprint layer is dried, an ink made of bronze powder, aluminum powder andaluminum paste is coated or otherwise a metal film is vapor-deposited onthe primary print layer, so that a metal layer 4 may be formed to impartan excellent decorative effect of appearance. In order to protect theunderside print layer against dissolution by a solvent, a mixtureincluding acryl resin or acrylicurethane resin, as the main component,mixed with a ketone-based solvent, an acetate-based solvent, oralcoholic solvent and also with a curing agent is coated on the metallayer 4 to provide a protective layer 5. The weight of resin for theabove-described primary print layer preferably amounts to 25 to 30 wt.%.

[0014] Thereafter, a thin secondary print layer 6 is laminated on theprotective layer 5 by coating a composition which is also prepared byusing acryl-based(MMA) resin or vinyl resin, small amount of additiveand pigment, and a solvent such as ketone-based solvent, acetate-basedsolvent or toluene. Finally, an adhesive layer 7 based onacryl-based(MMA) resin as the main component is formed on the secondaryprint layer 6 to provide the dissolution-type thermal transfer filmaccording to the present invention.

[0015] The thermal transfer film can be transferred, with the adhesivelayer facing the article, to the desired location on a wooden article orplastic molded product, wherein a pressing roller is rolled on thethermal transfer film at a speed of about 3 to 5 m/min at a temperatureof about 130° C. and subsequently dissolution steps by using the primaryand secondary solvents follow to provide decorative patterns withdesired shapes or expressions. In the above process, the adhesive layermay be uniformly coated on the laminate already formed by employing agravure cylinder.

[0016] In the following, the invention will be described in detail bymeans of working example.

EXAMPLE

[0017] On a polyester film, polypropylene film or polyvinylchloridefilm, or one of these kinds of films coated with a mat agent, i.e. aunglazed film, having the thickness of 12 to 25 microns, a releasingfilm (having the resin weight of 15 wt. %), a primary print layer ofwater-soluble or alcoholic resin (having the resin weight of 25 wt. %),a metal powder or metallic vacuum vapor-deposited layer, a thermalsetting protective layer, a secondary print layer and an adhesive layerare successively laminated to provide a dissolution type transfer filmfor three dimensional patterns according to the present invention.

[0018] Now, the transfer film so prepared is easily and rapidlytransferred to an article for decoration by press-rolling the film onthe article at a temperature of about 130° C. and at the roller speed ofabout 5 m/min. Subsequently a primary dissolution step is conducted,wherein the print layer 2 of water-soluble or alcoholic resin ispartially dissolved by a first designated solvent in a desired mannerand then a metal powder or metallic vacuum vapor-deposited layer 4 isalso partially dissolved by a second designated solvent to result in adesired final form of pattern. As the final step, drying is conducted.

Comparative Example

[0019] First a predetermined color is sprayed on an article fordecoration and fully dried, then a secondary spraying operation withgold and silver powder is conducted and fully dried, and as the nextstep, a water-soluble paint is sprayed on the metal powder layer,followed by a perfect drying. Subsequently, a primary dissolving andwashing is conducted to partially dissolve the water-soluble paint layerand a perfect drying is followed. Then, a secondary dissolving andwashing is conducted to remove the unnecessary part of the gold andsilver layer to provide a desired product.

[0020] The overall process requires much longer time than thecorresponding process part in the case related with the presentinvention.

[0021] As described above, the present invention rests on the process ofadhering a thermal transfer film in the dry state by using only heat andpressure and subsequently removing the surplus portions from the printedlayers by using two dissolution steps in forming a variety of threedimensional patterns on a picture frame, furniture, architecturalinterior parts and so on of wood or plastic molded materials, whereby amarked economical effect is attained, mainly due to the simplificationof the process, beside the excellent surface patterns.

What is claimed is:
 1. A dissolution type thermal transfer film forthree dimensional patterns, comprising: a base film consisting ofpolyester, polypropylene or polyvinylchloride without a mat agent orcoated with a mat agent to provide a unglazed film, an optionalreleasing layer based on acrylic resin as the main component havingseparability to be mounted on the top of the base film, a print layermade of a water-soluble acryl-based resin, or water-soluble or alcoholicvinyl-based resin having dissolving power, a metal powder-printed layeror metallic vapor-deposited layer, a thermosetting protective layer, asecondary acryl-based print layer and finally an adhesive layer coatedin that order.
 2. A method for manufacturing a dissolution type thermaltransfer film for three dimensional patterns, which comprises the stepsof: optionally coating the acryl-based resin, as the main component, byusing ketone-based solvent, acetate-based solvent or toluene to formreleasing layer, on a base film consisting of polyester, polypropyleneor polyvinylchloride without a mat agent or coated with a mat agent toprovide a unglazed film; on the releasing layer, coating the primaryprint layer consisting of an ink made from a water-soluble acryl-basedresin, or water-soluble or alcoholic vinyl-based resin together with adyestuff, methanol, ethanol, IPA and water; on the primary print layer,coating a metal powder ink or vapor depositing a thin metal layer invacuum; on the metal layer, coating a protective layer of acryl-basedresin or acrylicurethane-based resin including ketone-based solvent,acetate-based solvent, toluene, alcohol solvent and curing agent, as thelayer for preventing the under-laid printed layer from dissolving; onthe protective layer, coating a secondary print layer; and on thesecondary print layer, coating an adhesive layer for adhesion with anarticle to be joined.